Recent years have seen the rise of vibration problems associated with structures, which are more delicate and intricate, machines that are faster, more complex and production process that are automated and interlinked. The occurred problems are directly related to demands of lower investment, running and maintenance cost in incidence with the requirement of increase productivity and efficiency. This work developed aMachine Fault Simulator (MFS),whichis the most comprehensive laboratory scale machine on the market for performing rotor dynamics experiments.Also, it helps in learning vibration signature of the most common machinery faults in a controlled manner without compromising your quality production/ profits. The bench top system has a spacious modular design featuring versatility, operational simplicity and robustness in depth studies of a variety of faults can be conducted using over many applications. Some examples are rolling element bearing defects, Gear defect, belt and pulley defect, motor bearing defect.

1. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
DOI : 10.14810/ijmech.2015.4407 77
DESIGN AND DEVELOPMENT OF
MACHINE FAULT SIMULATOR (MFS)
FOR FAULT DIAGNOSIS
Chitresh Nayak1
,Vimal Kumar Pathak2
, Sagar Kumar3
. Prashant Athnekar4
1,2, 3, 4
Department of Mechanical Engineering, MNIT, Jaipur
ABSTRACT
Recent years have seen the rise of vibration problems associated with structures, which are more delicate
and intricate, machines that are faster, more complex and production process that are automated and
interlinked. The occurred problems are directly related to demands of lower investment, running and
maintenance cost in incidence with the requirement of increase productivity and efficiency. This work
developed aMachine Fault Simulator (MFS),whichis the most comprehensive laboratory scale machine on
the market for performing rotor dynamics experiments.Also, it helps in learning vibration signature of the
most common machinery faults in a controlled manner without compromising your quality production/
profits. The bench top system has a spacious modular design featuring versatility, operational simplicity
and robustness in depth studies of a variety of faults can be conducted using over many applications. Some
examples are rolling element bearing defects, Gear defect, belt and pulley defect, motor bearing defect.
KEYWORDS
Machine Fault Simulator, vibration analysis, rotating elements, fault diagnosis.
1. INTRODUCTION
Machinery fault diagnosis is finding a specific fault or failure that are produced in a system.
Condition based maintenance can significantly cut routine maintenance costs. Machinery
condition monitoring Covers distinctive disciplines such as mechanical measurements, electrical
measurements, performance and process measurement and tribology. Fault detection and
diagnosis can be broadly classified into two categories, i.e. Fault generator and Vibration
analysers. Fault generator is the Machine Fault Simulator (MFS) unit. MFS comprises of a shaft
rotor assembly driven by an AC motor.
MFS comprises facilities to introduce various machine faults like faulty bearings, damaged
gear and faulty belt drive [1]. Vibration Analyser hardware was used for vibration signal
acquisition & processing. The signal acquired was further processed in signal analysis software
[2].The early detection of faults can help avoid system shutdown, breakdown and even
catastrophes involving human fatalities and material damage. A systemthat includes the capacity
of detecting, isolating, identifying or classifying faults is called a fault diagnosis system [3]. The
common types of machine faultsareUnbalancing, Damaged or loose bearings, damaged gears,
Faulty of misaligned belt drive, mechanical looseness, increased turbulence and electrical induced
vibration.
Fault detection using vibration analysis involves analysing the vibration signature for signs of
fault. Any predominant fault occurring results in increased vibration level, which has energy
concentrated at certain frequency levels. The faultis not only based on the structure’s operating

2. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
78
environment, but also the type of monitoring system that is used [4, 5]. The common types of
gear damage mainly consist of pitting, scuffing, spalling, cracking and wear. One of the major
reasons for gear fault is excessive vibration [6]. Extensive literature is available on diagnosing
rolling element bearing defects using vibration analysis. Such as the effects of speed and damage
severity on the vibration signature. Authors have discussed different techniques for Machine fault
signature analysis of rotating elements [7]. Few author discussed gear fault feature based on
dominant intrinsic mode function [8].Machinery Fault Simulator (MFS) provides a platform to
study bearing faults. The following tests are performed on GYE25KRRB bearings with lightly
and moderately faulted outer race. The above literature presented provides an idea about the
development of MFS and their fault diagnosis techniques. The earlier MFS developed were costly
and complex in design. Also, the fault diagnosis was performed only for a few elements.
In the present work, the belt drive is not connected to prevent interference in the spectrum.
The faulted bearing is installed in the inboard bearing housing. Accelerometers are installed in
vertical and horizontal directions on the motor and two bearing housings. This work design and
developsan MFS for rotating elements to identify fault diagnosis and vibration analysis. The
basics and underlying physics of vibration signals are first examined. The latest approaches and
equipment used together with current research techniques in vibration analysis are also
highlighted in the paper. The Machine fault simulator developed is a low-cost set-up and simple
in design. Additionally, fault diagnosis can be performed for all rotating elements.
2. MACHINE FAULT SIMULATOR (MFS)
The simulator is designed, so that it is both easy to operate and versatile. The instrument is
constructed with special kinds of bearings, a split bracket bearing housing, multi-purpose belt
tensioning and gear mounting mechanism, and reciprocating system, all of which make it easy to
remove and replace various components for specific types of tests. Here are just a few of the
design features that make the Machinery Fault Simulator easy to use without sacrificing the
performance you need. The test rig consists of a three-shaft with agear on thefirst and second
shaft and two overhang pulleys on thesecond shaft and athird shaft, which is supported on the
bearings.
2.1 Proposed Methodology
This study is initialized as a first step towards evolving a model based diagnostic system for
rotating elements that will make full use of the information in the vibration data being collected.
The methodology for the MFS is based on characteristics of various types of vibration
encountered in rotating machinery. The framework for proposed methodologyis shown in
Figure1.
Figure 1. Proposed Methodology

3. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
79
2.2 Experimental Rig Design
An MFS has been designed and fabricated in order to demonstrate some of the most commonly
found faults in rotating machinery. The following faults can be illustrated using MFS:
misalignment (parallel and angular), imbalance, mechanical looseness, bent shaft, bearing fault,
gear fault, eccentric pulley, electric motor fault, vane passing frequency and missing blade.An
experimental test rig built to predict defects in GYE25KRRB bearing is shown in Table 1. The
test rig consists of a three-shaft with agear on thefirst and second shaft and two overhang pulleys
on second shaft and third shaft, which is supported on the bearings [9, 10]. The Experimental
setup for Vibration Based Fault Diagnosis of Rolling Element Bearings can be broadly classified
into two categories:FaultGenerator and Vibration analyzers. Fault Generator is the Machine Fault
Simulator (MFS) unit.
Machine Fault Simulator comprises of a shaft gear assembly driven by an AC Motor.
Machine Fault Simulator comprises facilities to introduce various machine faults like
misalignment, faulty bearings, damaged gear and faulty belt drive. The details of the bearing used
in the present are given in Table 1. FFT analyzer CSI 2400 Dynamic Vibration analyzer was used
to monitor vibration signals from good and defective bearings. The design of the machine fault
simulator is prepared by using Creo Parametric 2.0 and final isometric, and wireframe view is
shown in Figure 2.
Table 1. Roller Bearing Details [GYE25KRRB]
Figure 2. Isometric and wire frame view of machine fault simulator
Engineering structures and systems are designed to operate within limits specified by the
environment in which they will be used. At the design stage, the loading of the structure is
defined, and appropriate material choices are made based on their properties. In many cases,
prototypes are built, and stringent experimental testing is carried out. Increasingly, engineers rely
on modelling techniques to obtain knowledge of the structure'sbehavior in the operating
environment. The constructional parts of MFS are precision machined to high tolerances. It has
S No Parameter Value
1 Number of rollers 10
2 Outer diameter [mm] 52
3 Inner diameter [mm] 25
4 Pitch Diameter [mm] 39
5 Roller diameter [mm] 8

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80
a modular and flexible design for easy upgrades and installation. Use of rigid, slippage-free
operation using typical components from manufacturing. MFS includes removing and replacing
parts are couplings, bearings, shaft, pulleys, motor and belt can be changed without removing
bearing housing [11, 12].
2.3 Designing of Rotating Shaft
It is the rotating part of the rotor-bearing system. It consists of a solid steel shaft of diameter 28
mm and length 650 mm were used. A flexible coupling connects the rotor to the motor driver
shaft. Shafts with a heavy pre-load carried by the bearings, as distinct from the out-of-balance
load, can show variation characteristics similar to those caused by bearing misalignment. For
understanding behavior of shaft, variable load, equivalent stress, shaft based stiffness, torsional
rigidity and critical speed of shaft are considered. The mathematical calculation for the designing
of shaft 1 and shaft 2 are given below.
Let us take 45c8 steel and using electric motor having
Power 1 H.P=.75 KW
Power (P) = .75 kW = 750 W
Number of revolution per minute = 1440 rpm
Pressure angle (φ) 20°
For 45c8 steel (from design data Book)
Ultimate tensile strength 610 – 700 Mpa= σut
Take factor of safety = 6
σb or σt = 690/6 = 115 Mpa
τu = 0.75, σut= 0.75 × 690 = 517.5 Mpa
τs = τu /6 = 86 Mpa
DESIGN DIAMETER FOR SHAFT 1
Torque, T = P×60/2πN = 750×60/2π×1440
= 4.9736 Nm
Tensile force, Ft = 2T/D = 2×4.9736/210×10-3
= 47.3676 N
Resultant force, FR = Ft× tanφ =
47.3676×tan20
= 17.2404N
Total horizontal Load Ft = 47.3676N (→)
Total vertical Load = FR +W = 17.2404 + 50
d = 8.81 mm
Therefore, the nearest standard diameter of
the shaft being selected at 28 mm.
DESIGN DIAMETER FOR SHAFT 2
Torque P × 60 / 2πN = 750 × 60 2π × 1938
= 36.955 Nm
Tangential on gear at C
Ft = 2T/D = 2 × 36.955/156 × 10-3
= 473.788 N
Load = Normal Load acting on gear
W = Ft / cosφ = 504.194 N
Horizontal component of load W
= 22.2404 N (↓)
Moment
M = Wab/l ⇒ 22.2404×0.2×0.4/0.6
= 2.9022
M = Wab/l ⇒ 47.3676×0.2×0.4/0.6
= 6.3156
Resultant Moment
M = √ (2.9022) 2
+ (6.3156) 2
= 6.9505 Nm
Maximum shear stress theory: -
Te = √M2
+T2
=π/16 τd3
Te = √(km×M) 2
+ (Kt × T) ²
Km = Shock and fatigue factor applied to
bending moment
Kt = Shock and fatigue factor applied to
torsion moment
Take the value from design data book.
Km = 1.5 and Kt =1
Te = √ (1.5×6.9505) ² + (1×4.9736) ²
11.55×10³ = π /16 × 86 × d³
Vertical Load due to pulley at D
Wpv = Weight of pulley = 11.772N
Vertical moment diagram
RAV + RBv = 473.78 + 11.772
= 485.552
Taking moment about A
RBV × 0.6 = 473.78 × 0.2 + 11.77 × 0.65
RBV = 170.677
RAV = 485.552 – 170.677
RAV = 314.874
Vertical banding moment at C & D
MVC = RAV × 0.2 = 62.97 Nm

5. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
81
WH = W × sinφ
= 172.44
Vertical component of Load W
WV = W × cosφ
= 504.194 × cos 20
= 473.78
Pulley (1) have 5” = diameter = 127 mm then
assume = 128 mm
Weight of pulley = 1.2 kg = 11.772 N
Half groove angle (β) = 22º, µ = 0.30, =180
Torque = T = (T1-T2)r
36.955 = (T1-T2) 128/2
T1-T2 = 577.5 N
(T1/T2) = e µθcosecβ
T1/T2 = e 0.3 ×π×cosec22º
T1/T2 = 12.384 or T1 = 12.384 T2
T2 = 50.73
T1 = 628.221
Horizontal Load due to pulley at D
Wph = T1 + T2
= 678.951 N
Te = √M² + T²
Te = √M2
+T2
=π/16 τd3
Te = √(km×M) 2
+ (Kt × T) ²
π / 16 × 86 × d³ =√ (64.043) ² + (36.9) ²
MVD = RBV × 0.05 = 8.533 Nm
RAH + RBH=172.44+679
= 851.44 N
Taking moment about A
RBH × 0.6 = 679× 0.65 + 172.44× 0.2
RBH = 793.063 N
RAH = 851.44 – 793.063
= 58.376 N
Horizontal banding moment at C & D
MHC = RAH × 0.2 = 58.376× 0.2
= 11.675 Nm
MHD = RBH × 0.05 = 793.063 × 0.05
= 39.653 Nm
Resultant banding moment at C
MC = √ (MHC) ² + (MVC) ²
= √ (64.043) ² + (62.97) ²
= 64.043N
MD = √ (MHD) ² + (MVD) ²
= √ (39.653) ² + (8.533) ²
= 40.560N
Taking larger value of 64.043 Nm
Maximum shear stress theory: -
π / 16 × 86× d³ =73.87 × 1000 N-mm
π / 16 × 86× d³ = 73.87 Nm
d = 16.95 mm
Therefore nearest standard diameter of shaft
being selected at 28 mm.
3. RESULTS
The machine fault simulator developed (see Figure 3) in this work is capable of accurate analysis,
thefault of machine element and its causes. Machine fault simulators can diagnosis regarding
vibration, noise, wear, lubrication.Helical gear was usedfor the purpose of high strength and low
noise. Easy to install gears of different sizes/types, and to introduce a variety of faults for
controlled studies.
Figure 3. Various possible Fault locations
Frame Bearing GearBelt Drive MotorCoupling

6. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
82
Maintenance of machine can be carried out very fast in regarded to thediagnosis of the problem
thatreduces investment cost of machine, ideal time of plant, reduce non-productive man hours.
Hence, it also increases productivity, quality, effectiveness, efficiency, consistency of the product.
Torque, vertical-horizontal load, vertical-horizontal and resultant bending moment test were
performed on the shaft. The results for above tests were shown below in Figure 4. A and B are
bearing, C is helical gear and D is acoupling of the developed MFS as depicted in Figure. During
testing of proposed system, it was observed that with rotation of the motor at 1440 RPM,vertical
load on gear C is 473.78 N (↓) and horizontal load is 172.44 N in a downward direction. The
vertical load on coupling 11.772 N (↓) and thehorizontal load is 678.95 N (↓). A resultant bending
moment on gear and coupling are 64.04 Nm and 40.50 Nm respectively. The results shown are by
the standards defined.
Figure 4. Line diagram of Torque, Load and Moment for MF
CONCLUSION
The Machine Fault Simulator is an essential tool for analysis, development for vibration.An
investigation into factor affecting the development of a Machine Fault Simulator for fault
diagnosis in bearing machine fault are affected by vibration, noise, wears, lubrication, moisture,
and dust. Studies can be performed on the vibration spectra of common faults, learn fault
signatures, vibration based diagnostic techniques, lubricant condition and wear particle analysis.
The parameter should be maintained for better performance of the system. A Gear diagnostic
and prognostic method was developed. This system highlights the discrepancy in gear diagnosis
and prognosis due to many hidden factors beyond just the operating condition. The methodology
can be extended to other gear where geometries of gear and materials are different.Different
speeds of three shafts allow demonstration of frequency analysis methods.

7. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
83
The future scope includes study the temperature pattern and find out the best location to put
temperature sensor or any other way to get maximum available temperature. Find out the best
location and the environment to sense the fault signature sound. To enclose the gear within the
gearbox within the gearbox filled with oil, one gear is made by brass and another gear is made of
cast iron that could be used for wear test through oil analysis. Designed in parallel shaft gearbox
can be configured as single/double stage reduction/increase. Easy to install gears of different
sizes/types, and to introduce a variety of faults for controlled studies. We can assemble rotors
with split collar ends for easy replacement and installation of the shaft that is connectedto
coupling motor. The helical gear is made of brass because of reduce noise and
vibration.Additional devices may be mounted on the output shaft.
REFERENCES
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[2] Y. H. Kim, B.D. Lim, and W.S. Cheoung. (1991) “Fault Detection in a Ball Bearing System Using a
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[3] P. W. Tse, W. Yang, and H. Y. Tam. (2004) Machine fault diagnosis through an effective exact
wavelet analysis. Journal of Sound and Vibration, 277:1005–1024.
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Authors
Mr. ChitreshNayak is Research scholar in Mechanical Engineering
at Malaviya National Institute of Technology Jaipur (Rajasthan,
India). He did his graduation at RGPV University Bhopal and
M.Tech at MITS Gwalior both in MechanicalEngineering. His
research interests include Reverse Engineering and rapid prototyping.
He has about 10 journal and conference publications in his credit.

8. International Journal of Recent advances in Mechanical Engineering (IJMECH) Vol.4, No.4, November 2015
84
Mr. Vimal Kumar Pathak is Ph.D. research scholar in Department of
Mechanical Engineering at Malaviya National Institute of Technology,
Jaipur, India. He has done his masters from ISM Dhanbad (now IIT
Dhanbad) in Maintenance Engineering and Tribology. His area of
interests are advanced tribology, Reverse Engineering, Rapid
Prototyping, Automatic inspection, Optimization, Geometric
Dimensioning and Tolerancing.
Mr. Sagar Kumar is Ph.D. research scholar in Department of
Mechanical Engineering at Malaviya National Institute of Technology,
Jaipur. He has done his Masters from VNIT, Nagpur in CAD/CAM. His
area of Interests are Tribology, Rapid Tooling, Reverse Engineering and
CAD/CAM/CAE.
Mr. Prashant Athnekar is Ph.D. research scholar in Department of
Mechanical Engineering at Malaviya National Institute of Technology,
Jaipur. He has done his Masters from SGSITS Indore in Computer
Integrated Manufacturing. His area of Interests are Tool Design and
Development, Rapid Tooling, Reverse Engineering and Mold Design.